Sensor bracket

ABSTRACT

A sensor bracket includes a bracket on which a camera detecting a state around the vehicle is mounted, a planar portion that holds the camera to the bracket by engaging with an engagement protrusion of the camera, a flat spring that biases the camera in a direction that maintains an engaged state of the camera by abutting against the camera when the camera is mounted on the bracket, a projecting structure of the bracket that restricts a defamation range of the flat spring displaced in an engagement direction of the engagement protrusion within an elastic deformation range when the engagement protrusion is engaged with the planar portion while the camera is abutted against the flat spring.

CROSS REFERENCES TO RELATED APPLICATIONS

The present application claims priority under 35 U.S.C. § 119 to Japanese Patent Application No. 2016-060374, filed Mar. 24, 2016, entitled “Sensor Bracket.” The contents of this application are incorporated herein by reference in their entirety.

BACKGROUND 1. Field

The present disclosure relates to a sensor bracket used to attach an on-board camera or the like.

2. Description of the Related Art

Hitherto, a technique is known that accurately detects an obstacle and a pedestrian, a position of a traffic lane, whether a headlight of an oncoming vehicle is on, and the like by performing imaging of a portion in front of a vehicle with an on-board camera. In such a case, the on-board camera is mounted on a bracket that is attached to a windshield.

For example, in Japanese Unexamined Patent Application Publication No. 2013-203250, while bosses of an on-board camera main body are hooked to hook-shaped portions, the on-board camera main body is slid from below towards an obliquely upward portion at the rear side and along a glass surface of the windshield to attach the bracket. When performing the above operation, first, the rear surface of the on-board camera main body comes into contact with a flat spring, and the flat spring is pushed and defamed by the on-board camera main body.

Furthermore, in a state in which the on-board camera main body is biased towards the front by the flat spring, an engagement protrusion of the on-board camera main body inserted into engagement holes of the bracket is abutted against the front side end portion such that an upper surface of the on-board camera main body is abutted against a back surface of an adhesion portion of the bracket (a surface that is on the side that opposes the on-board camera main body). With the above, the on-board camera main body is fixed while the front side thereof is biased against the bracket with the flat spring (Japanese Unexamined Patent Application Publication No. 2013-203250, paragraphs 0040 to 0043, FIGS. 1 and 5).

SUMMARY

Since the flat spring of Japanese Unexamined Patent Application Publication No. 2013-203250 biases the on-board camera body only in the front direction, the on-board camera body may be unstable in the up-down direction. Accordingly, one may conceive of providing a spring that biases the on-board camera body in the up-down direction in the bracket.

However, as in the bracket of Japanese Unexamined Patent Application Publication No. 2013-203250, in a case in which an adhesion portion adhered to a surface of a piece of glass is famed in a planar shape, when the on-board camera body is attached, the spring is pressed hard in the up-down direction and becomes elastically deformed, such that the biasing force of the spring becomes weak disadvantageously causing the on-board camera to be mounted on the bracket in an unstable manner.

The present disclosure has been made in view of the above situation and describes a sensor bracket that is capable of reliably mounting a sensor, such as an on-board camera that detects a state around the vehicle.

A sensor bracket of the present disclosure includes a bracket body attached to a vehicle, a sensor being mounted on the bracket body and detecting a state around the vehicle; a sensor holding portion provided in the bracket body, the sensor holding portion holding the sensor to the bracket body by engaging with an engagement protrusion formed in the sensor; a spring member provided in the bracket body, the spring member abutting against the sensor and biasing in a direction that maintains an engaged state of the sensor when the sensor is mounted on the bracket body; and a restriction portion that is provided in the bracket body, the restriction portion restricting a deformation range of the spring member displaced in an engagement direction of the engagement protrusion within a predetermined elastic deformation range when the engagement protrusion is engaged with the sensor holding portion while the sensor is abutted against the spring member.

According to the sensor bracket of the present disclosure, when the operator attaches the sensor to the bracket body, the spring member abuts against the sensor from a first position and is defamed during the further movement to a second position, which define a deformation range of the spring member, i.e., a displacement distance of the defaming end of the spring member due to the engagement movement in the engagement direction; however, the restriction portion is provided such that it restricts the deformation range of the spring member within the predetermined elastic defamation range considered to be acceptable to the spring member because the restriction portion is configured to abut the sensor and prevents further deformation of the spring member when the spring member reaches the second position. Accordingly, the biasing force of spring member can be prevented from decreasing due to plastic deformation and the sensor can be mounted on the bracket body in a stable manner.

In the sensor bracket of the present disclosure, preferably, the restriction portion abuts against a predetermined portion of the sensor when the sensor is mounted on the bracket body, and the predetermined portion and a portion of abutment have the same shape.

According to such a configuration, since the abutting portion of the restriction portion of the bracket body has the same shape as the shape of the sensor, when the sensor is mounted on the bracket body, the sensor and the bracket body are abutted against each other in a wide area. With the above, the pressure of the sensor during attachment does not concentrate on a specific position and the sensor and the bracket body can be prevented from becoming damaged.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating a configuration of a sensor bracket of the present disclosure on which a camera is mounted.

FIG. 2 is a perspective view of the whole camera.

FIG. 3 is a perspective view of an upper surface side of the entire bracket.

FIG. 4 is a side view of the bracket on which the camera has been mounted.

FIG. 5 is a perspective view of a lower surface side of the entire bracket.

FIG. 6 is a diagram illustrating a state in which the bracket is attached to a windshield.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates a configuration in which a camera corresponding to a sensor of the present disclosure that detects the surroundings of a vehicle is mounted on a sensor bracket of the present disclosure. Hereinafter, the above configuration is referred to as a camera unit 1.

FIG. 1 is a perspective view of the camera unit 1 viewed obliquely from above. The camera unit 1 includes a camera 2 that is a sensor that performs imaging of an image in front of the vehicle, and a bracket 3 that is fixed to the windshield of the vehicle by being adhered thereon. Note that, hereinafter, description is given while the front of the vehicle is a front direction (a front side).

As illustrated in the drawings, the camera 2 is mounted on the bracket 3 from a lower side of the bracket 3 with an engaging mechanism described later. An opening 3 b into which a lens 2 a of the camera 2 is inserted is provided on an upper surface of the bracket 3. With the above, the camera 2 is capable of performing imaging of an image in front of the vehicle.

Next, FIG. 2 is a perspective view of the camera 2 viewed obliquely from above. The lens 2 a is attached to an upper surface of the camera 2. Furthermore, a groove portion 2 b that widens at an angle towards the front is formed on a front side of the lens 2 a. While the details will be described later, a cavity 3 a′ that has a shape that is the same as that of the groove portion 2 b is formed in the upper surface of the bracket 3 as well, so that the field of view of the lens 2 a is not blocked.

Furthermore, both sides of the upper surface of the camera 2 are inclination portions 2 c that incline downwards towards the front side. Since the front side of the bracket 3 is down when the bracket 3 is fixed to the windshield, by forming the inclination portions 2 c on the upper surface of the camera 2, the entire upper surface of the camera 2 comes in contact with the bracket 3. Note that hook portions 2 d are provided at the front end of the camera 2 and are engaged with hole portions 3 c of the bracket 3 described later.

An engagement protrusion 2 e is provided on a rear surface of the camera 2. The engagement protrusion 2 e is a member for mounting the camera 2 on the bracket 3. While the details will be described later, in a state in which the camera 2 is mounted on the bracket 3, the engagement protrusion 2 e presses flat springs 4 (spring members of the present disclosure) included in the bracket 3, and the lock portions 3 g press, from below, the engagement protrusion 2 e that has received biasing force and fixes the camera 2 to the bracket 3.

Referring next to FIGS. 3 to 5, a structure of the bracket 3 will be described.

FIG. 3 is a perspective view of the upper surface side of the bracket 3 viewed obliquely from above. The opening 3 b is provided at substantially the middle of a planar portion 3 a of the upper surface of the bracket 3, and the cavity 3 a′ that widens at an angle towards the front is formed on the front side of the opening 3 b.

The cavity 3 a′ has a stray light shielding structure (an antireflective shape) in which a number of grooves are famed so that the reflected light is not directly incident on the lens 2 a. The cavity 3 a′ is slightly curved at the distal end side of the bracket 3 in a direction away from the windshield when the bracket 3 is attached to the windshield. With the above, only the bracket 3 can be seen from the black ceramic cutaway of the windshield; accordingly, the well-formed appearance can be maintained.

Furthermore, the hole portions 3 c with which the hook portions 2 d of the camera 2 are engaged are formed at both sides of the cavity 3 a′. The hole portions 3 c protrude towards the undersurface side of the bracket 3, and only the rear portions are open. Accordingly, when the camera 2 is mounted on the bracket 3, the hook portions 2 d are accommodated in the recessed portions of the hole portions 3 c (see FIG. 4).

An engaging mechanism to which the engagement protrusion 2 e of the camera 2 is engaged is famed on the rear surface of the bracket 3. Specifically, as illustrated in FIG. 4 as well, the engaging mechanism includes, in the order from the rear end side of the bracket 3, stoppers 3 d, projections 3 e for the springs, and the lock portions 3 g.

The stoppers 3 d are restriction members that avoid a tool from hitting the windshield when the flat springs 4 attached to the projections 3 e for the springs are dismounted. As illustrated in FIG. 4, the rear end portions of the flat springs 4 (made of aluminum, for example), which are attached to the projections 3 e for the springs so as to be wound therearound, slightly project towards the stoppers 3 d.

When dismounting the flat springs 4 from the projections 3 e for the springs after the camera 2 has been separated from the bracket 3, the operator needs to press the rear end portions of the flat springs 4 from the lower side with a tool, such as a slotted screwdriver. In so doing, the L-shaped wall portions of the stoppers 3 d function to restrict the displacement of the tool so that the tool having momentum does not damage the windshield by moving through to the windshield.

Recesses 3 f are structures used when the operator attaches the flat springs 4 to the projections 3 e for the springs, and are famed at positions adjacent to the projections 3 e for the springs. The flat springs 4 can be fitted (temporarily fitted) into the projections 3 e for the springs to a certain degree by pressing the flat springs 4 from the upper side of the projections 3 e for the springs with the tool.

However, if the flat springs 4 are not completely fitted into the projections 3 e for the springs, the flat springs 4 will come off when pressed by the engagement protrusion 2 e of the camera 2. Accordingly, the operator completely fits each flat spring 4 to the corresponding projection 3 e for the springs by pressing the flat spring by rotating the tool while the tip of the tool is abutted against the corresponding recess 3 f. By receiving the tip of the tool in the recess 3 f, the displacement of the tool is restricted and, accordingly, the windshield and the like are not damaged during the operation. In other words, formation of the stoppers 3 d and the recesses 3 f in the bracket 3 enables the operator to perform the operation at ease when, due to damage and plastic defamation, replacing the flat springs 4.

The lock portions 3 g are members that fix the camera 2 in the up-down direction when the camera 2 is mounted on the bracket 3. The projections 3 e for the springs are provided on the lateral side of the bracket 3 so as to project externally with respect to the stoppers 3 d, and the flat springs 4 are attached to the projections. Furthermore, the lock portions 3 g receive biasing force from the flat springs 4 through the engagement protrusion 2 e of the camera 2.

When the camera 2 is mounted on the bracket 3, the operator slides the camera 2 so that the hook portions 2 d of the camera 2 enter the hole portions 3 c of the bracket 3 and, further, fixes the camera 2 such that the engagement protrusion 2 e of the camera 2 presses the flat springs 4 upwards. In so doing, the engagement protrusion 2 e moves while abutting against the undersides of the lock portions 3 g and reaches a position where the engagement protrusion 2 e presses the flat springs 4.

Furthermore, as illustrated in FIG. 4, the engagement protrusion 2 e is pressed downwards with the biasing force of the flat springs 4 and the engagement protrusion 2 e is caught by the distal end of the lock portions 3 g. In other words, the lock portions 3 g guide the engagement protrusion 2 e to the engagement position. Since the flat springs 4 biases the engagement protrusion 2 e downwards within the elastic deformation range, the camera 2 can be mounted on the bracket 3 in a stable manner.

On the other hand, when separating the camera 2 from the bracket 3, the operator abuts a finger against a rear outer wall 3 h, which is behind the stopper 3 d, and rearwardly pulls out the camera 2; accordingly, the flat springs 4 are pressed upwards and the engagement protrusion 2 e is detached from the lock portions 3 g. In other words, the camera 2 can be separated from the bracket 3 by sliding the camera 2 rearwardly in one direction.

Furthermore, immediately before the camera 2 is separated from the bracket 3, the rear end of the camera 2 abuts against vertical ribs 3 i positioned between the stoppers 3 d and the projections 3 e for the springs. Since the vertical ribs 3 i are positioned on the trajectory (extending in the sliding direction) of the dismounted camera 2, movement of the camera 2 is restricted such that when the camera 2 is separated from the bracket 3, the camera 2 is prevented from abruptly moving out. Furthermore, since the movement of the camera 2 is restricted by the vertical ribs 3 i, unnecessary stress is not applied to the flat springs 4 any more when the camera 2 is separated from the bracket 3. Accordingly, plastic deformation of the flat springs 4 can be prevented from occurring.

FIG. 5 is a perspective view of the lower surface side of the bracket 3 viewed obliquely from above. The opening 3 b is provided in substantially the middle of the lower surface of the bracket 3, and a projecting structure 3 j corresponding to a restriction portion of the present disclosure is provided at a position lateral to the opening 3 b. Since the shape of the lower surface of the bracket 3 is the same as the shape of the upper surface of the camera 2, the upper surface of the camera 2 abuts against the bracket 3 in a wide area when the camera 2 is mounted on the bracket 3. With the above, the pressure of the camera 2 during attachment does not concentrate on a specific position and the camera 2 and the bracket 3 can be prevented from becoming damaged.

A bottom-plate spring 5 that biases the camera 2 downwards (the upper direction in FIG. 5) is attached on the rear side (the upper side of the figure) of the hole portions 3 c. Although the bracket 3 of the present exemplary embodiment only has a single bottom-plate spring 5, two bottom-plate springs 5 may be provided on the rear side of the two hole portions 3 c.

Furthermore, the vertical ribs 3 i are provided between the stoppers 3 d and the projections 3 e for the springs. Although narrow in width, the vertical ribs 3 i include wall surfaces that are orthogonal to the sliding direction in which the camera 2 is separated.

Reference surfaces A to D that are cut in a planar manner and that are parallel to each other are provided in the four corners of the bracket 3 on the lower surface side. Furthermore, when the bracket 3 is attached to a curved windshield, portions in the planar portion 3 a that are opposite the reference surfaces A to D are, as adhesion surfaces, adhered to the windshield with double-sided tapes. In so doing, there are cases in which the bracket 3 is inclined slightly; however, by measuring the distances between the reference surfaces A to D and the windshield, the inclination of the bracket 3 with respect to the windshield can be measured.

Hereinafter, a method for calculating the angle of the bracket 3 with respect to the windshield will be described. FIG. 6 illustrates a state in which the bracket 3 is adhered to a windshield 7 with a double-sided tape 8. In the above, X is the distance between the reference surface A and the reference surface B of the bracket 3. Furthermore, distances between each of the reference surfaces and the windshield, such as a distance h1 between the reference surface A and the windshield 7 and a distance h2 between the reference surface B and the windshield 7, are measured. Note that a distance Y of the gap on the upper side of the reference surface B in the drawing between the bracket 3 and the windshield 7 is the difference between the distance h2 and the distance h1, that is, |h2−h1|.

With the above, an inclination angle θ of the bracket 3 attached to the windshield 7 can be obtained by tan θ=Y/X.  (1) Since the camera 2 mounted on the bracket 3 has the same inclination angle θ, correction of the axis deviation can be made easily.

In actuality, although there are double-sided tapes 8 (with a thickness of about 0.8 mm) above the reference surfaces A and B, a slight inclination created by the thickness of the double-sided tapes 8 can be absorbed. As described above, when controlling the inclination of the bracket 3, the inclination angle θ can be calculated and correction thereof can be made if there are (at least three) flat surfaces such as the reference surfaces A to D.

As described above, the camera unit 1 of the exemplary embodiment includes the camera 2 that detects the state around the vehicle, and the bracket 3 attached to the inner surface of the windshield of the vehicle, and the camera 2 is mounted on the bracket 3. In the above, the camera 2 is biased by the flat springs 4 in a direction that maintains the engaged state of the camera 2 and is restricted within the elastic deformation range by the projecting structure 3 j of the bracket 3. With the above, the camera 2 can be mounted on the bracket 3 in a stable manner.

The exemplary embodiment described above is an example of the present disclosure and various modifications can be made. In the exemplary embodiment described above, while the camera 2, which serves as a sensor of the present disclosure that detects the state around the vehicle, has been illustrated, the sensor may be other types of sensors such as a radar device.

Furthermore, while the bracket 3 is made of metal, not limiting the material to any material, the bracket 3 may be molded of plastic or the like. While the engaging mechanism of the bracket 3 is positioned on the rear side of the bracket 3, there is no restriction in the position and, for example, the spring members and the lock portions may be provided at areas that cannot be partially or totally seen from the outside. 

What is claimed is:
 1. A sensor bracket comprising: a bracket body attached to a vehicle having a sensor holding portion; a sensor configured to detect a state around the vehicle and having an engagement protrusion which is configured to engage with the sensor holding portion of the bracket body, thereby holding the sensor to the bracket body; a spring member provided in the bracket body, the spring member abutting against one side of the sensor and biasing the sensor in a direction that maintains an engagement between the engagement protrusion of the sensor and the sensor holding portion of the bracket body in a state where the sensor is mounted on the bracket body, the spring member moving from a first position to a second position in an engagement direction to complete the engagement, the spring member starting abutting against the sensor in the first position and then being deformed upon the movement to the second position; and a restriction portion provided in the bracket body such that the restriction portion abuts an upper surface of the sensor in a physical contact manner when the spring member reaches the second position, thereby restricting a deformation of the spring member in the engagement direction that pushes the spring member so as to be within an elastic deformation range predetermined for the spring member, wherein the restriction portion is a rib structure projecting from the bracket body in a vicinity of the sensor holding portion thereof, a ridge of the rib abutting against the predetermined portion of the sensor when the sensor is mounted on the bracket body.
 2. The sensor bracket according to claim 1, wherein the restriction portion has a portion which abuts against a predetermined portion of the sensor at the upper surface thereof when the sensor is mounted on the bracket body, the predetermined portion of the sensor and the portion of the restriction portion having a shape corresponding to each other. 